Compactor device

ABSTRACT

A compactor device for the automatic compacting of empty containers ( 5 ), e.g. disposable bottles/cans of metal, plastic, glass or other suitable material, wherein the container ( 5 ) is essentially being pressed flat and possibly punctured, possibly crushed, and wherein the compacting area is formed by a cuneiform area between a conveyor belt ( 20 ) and a first jaw set ( 36   a ) and a second jaw set ( 36   b ), and wherein a plurality of jaws ( 32 ), which are provided with teeth on their active side, are arranged in such a way that each alternate jaw ( 32 ), as seen transversally to the longitudinal direction of the conveyor belt ( 20 ), is connected to the jaw sets ( 36   a ) and ( 36   b ) respectively, the jaw sets ( 36   a ) and ( 36   b ) being rotatably connected to two common eccentric shafts ( 38, 38′ ), and the eccentric shafts ( 38, 38′ ) being formed in such a way that the eccentric motion of the jaw sets ( 36   a   , 36   b ) is out of phase, typically by 180 degrees.

[0001] The present invention relates to a device for the automaticcompacting of empty containers, for example disposable bottles and cansof metal, plastic, glass or other material suitable for such containers.The device is particularly suitable as part of a reverse vending machinewhich receives used beverage packaging.

[0002] In the receipt and transport of empty containers it is desirablethat the used packaging in the form of bottles and cans should occupythe smallest possible volume to reduce the transport costs.

[0003] In reverse vending machine installations for automatic receipt ofpackaging there is also a need for reducing the space that this materialoccupies behind the return insert opening because this space is oftenlimited. Additionally, it is also important that said machine has aslarge a storing capacity as possible to prevent having to empty thecollecting receptacles too often. Such emptying entails disturbance inthe work of those responsible for emptying the receptacles, typicallythe staff of grocery stores, who want mainly to spend the time assistingcustomers.

[0004] In a reverse vending machine installation it is also importantthat the empty packaging is deformed in such a way that it cannot passseveral times through the machine. Thereby swindle is prevented. Such afunction is also a requirement in many return systems, in which a returnvalue is paid on return of the empty packaging as for example bottlesand cans.

[0005] It is normally expected that the packaging items are compactedindividually, without the packaging item being divided into severalpieces, which simplifies the sorting of the different types of materialin a subsequent processing. However, compacting of glass is normallydone by smashing, so that the glass is divided into many smallerfragments. It is desirable that one and the same compactor should allowcompacting of several types of packaging, as for example plasticbottles, steel cans, aluminium cans and glass bottles of volumes from150 millilitres to 3 litres, in order to minimize the number of modulesin a reverse vending machine such as described above.

[0006] It is important for these types of devices to be robust and notrequire frequent repairs and maintenance.

[0007] Devices for automatic compacting of used beverage containers,which may handle plastic bottles, steel cans and aluminium cans, areknown from i.a. U.S. Pat. No. 5,522,311 and WO 00/40397. From thesedocuments it is known to use two endless belts pressing the packagingbetween themselves in V-shaped funnel. Devices for the automaticcompacting of cans exclusively or plastic bottles exclusively are knownfrom a number of patents and patent applications, but this technology isconsidered to fall outside the object of the device according to theinvention.

[0008] Compactors for use in a reverse vending machine installationwhich is arranged to allow compacting of containers of plastic, metaland glass are not known.

[0009] So-called belt compactors which are based on endless beltsproduced of a flexible material are often provided with a number ofstuds mounted on the belts for puncturing and gripping packaging. Adevice of this kind, as it is described in U.S. Pat. No. 5,522,311, issubject to great wear. In particular, it is-a disadvantage that thestuds, which are formed of a hard material, e.g. steel, are mounted inthe flexible belt which is produced from a soft material, e.g. rubber.The rubber is worn by both friction and forces acting between thecontainers and the belt and forces between the studs and the rubber ofthe belt.

[0010] So-called belt compactors utilize endless belts consisting ofrigid plates hinged together, such as described in WO 00/40397. Thistype of compactor is formed of a great number of parts which moveindividually relative to each other. Each of the so-called hinges issubjected to wear as packaging is being compacted.

[0011] Wear entails high operating costs for the device and unnecessarystoppage in connection with service.

[0012] In all belt compactors, after having been punctured, containersmust follow the belt all the way over the rollers that drive the belt.This means that it will be difficult for the compactor to be constructedin such a way that the compacting times will be optimal. The compactingsequence for a plastic bottle typically consists of gripping, puncturingand pressing flat. For a can, puncturing is normally not necessary.

[0013] Belt compactors are not suitable for compacting/breaking glassbecause the pressure of the belt is normally distributed across toolarge an area for the glass to be broken.

[0014] The object of the invention is to provide a compactor which iscapable of quick, simple and efficient compacting of empty containers,so that costs related to handling, storing and transport are reduced,while at the same time the containers are destroyed in such a way thatrecognizable properties, e.g. shape, are changed so much that repeatedinsertion into a reverse vending machine with subsequent additionalpayment of return value will not be possible.

[0015] A compactor according to the invention is provided with two setsof jaws, so-called jaw sets, in which each jaw is formed as a rod, andin which the underside of the rod, which comes to rest on thecontainers, is formed with teeth. The jaws are supported on twoco-rotating eccentric shafts that make the jaws move in an eccentricparallel motion during operation. The two jaw sets are formed in such away that each alternate jaw, as seen transversally to the movingdirection, belongs to a first jaw set, whereas the other jaws belong tothe second jaw set. The jaw sets are supported on common shafts, but are180 degrees offset relative to the centres of rotation of the shafts.The jaw sets are placed at an angle above a conveyor belt, so that thedistance between the jaw sets and the conveyor belt is the smallest atthe outlet end portion of the belt.

[0016] The compactor may be provided with partition walls placed betweentwo jaws, thus forming two or more parallel channels through thecompactor. The teeth of the jaws may be formed differently in thechannels, as each tooth of one set of teeth, individually or in groups,may be formed in such a way that the tooth/teeth perform a particulartask, such as gripping, puncturing, hammering or crushing. In thefollowing an area of such a particular task is called a segment.Segments of a jaw may also be without teeth if this is desirable, e.g.in order to achieve flat-pressing. Each jaw is formed individually toexert optimum compacting of a type of packaging, e.g. metal, plastic orglass.

[0017] On the portions of the jaws that are intended for compactingplastic bottles, the teeth of at least a portion of the set of teeth areformed so that they have at least two peaks beside each other relativeto the longitudinal direction of the jaws. Thereby the teeth grip thebottle at the same time as the bottle is being punctured.

[0018] The conveyor belt comprising an endless band and necessarydriving elements carries containers in below the jaw sets. Below theconveyor belt itself is mounted a support plate which acts as aholding-up means for the jaws during compacting.

[0019] With respect to angle and distance relative to the conveyor beltsegments of each jaw may be so formed that method and degree ofcompacting may be selected for each channel.

[0020] At its feeding portion the conveyor belt is hinged to thestructure of the compactor. A spring mechanism, e.g. in the form of agas spring, is arranged between the discharge end portion of theconveyor and the structure of the compactor. The spring mechanism isarranged to limit the maximum force that may be applied to a containerbetween the band and the jaws.

[0021] If a container or another object, which does not allowcompacting, enters the compactor, the spring device will yield, so thatthe object can be carried through the compactor without damaging thecomponents thereof. If the object is too large to be carried through thecompactor, the belt conveyor will be subjected to a force which causesthe release of a switch and the compactor is stopped. The springmechanism may then be released and the belt conveyor lowered, so thatthe object may be removed.

[0022] In the following is described a non-limiting example of apreferred embodiment which is visualized in the accompanying drawings,in which:

[0023]FIG. 1 shows the compactor in a side view, seen from the gasspring side;

[0024]FIG. 2 shows the compactor in a side view, seen from the feedingside;

[0025]FIG. 3 shows the compactor, partly in a sectional side view, seenfrom the driving side;

[0026]FIG. 4 shows the jaw operation of the compactor, seen from above;

[0027]FIG. 5 shows, in perspective, a jaw with teeth for the compactingof plastic containers; and

[0028]FIG. 6 shows the compactor in a side view, seen from the gasspring side in a state of operation, in which the conveyor belt is in alower position.

[0029] In the drawings the reference numeral 1 identifies a compactorcomprising a structure 10, a conveyor belt 20 and a jaw device 30. Thestructure 10 is provided with sidewalls 12, 12′ arranged to absorb theforces from the jaw device 30 and form a securing point for a drivingmotor 22 and pivoting point 23 of the conveyor belt 20 and rotationalpoint 15 for a release arm 14. A gas spring 16 is connected to therelease arm 14. The operation of the release arm 14 will be describedbelow.

[0030] Besides the combined drive roller/motor 22 the conveyor belt 20comprises a frame structure 24 comprising a support plate 26, a belt 28and a turning roller 29.

[0031] The jaw device 30 is placed above the conveyor belt 20, and issloping down towards the turning roller 29. The jaw device 30 isconnected to the sidewalls 12 by means of bolts 31 and is therebyarranged to allow easy dismantling for maintenance or replacement. Twosets of jaws 32, see FIG. 5, are connected to a mounting plate 34 each.Tow mounting plates 34, 34′ and a number of jaws thus form a jaw set 36,see FIG. 4. Tow jaw sets 36 a and 36 b are rotationally supported on twocommon eccentric shafts 38, 38′, so that the supports of the jaw setsare rotated through 180 degrees relative to one another relative to thecentre of rotation of the eccentric shafts 38, 38′. The eccentric shafts38, 38′ are rotatably secured to the sidewalls 12, 12′ and driven by anelectric motor 40 through a belt transmission 42.

[0032] Seen transversally to the longitudinal axis of the conveyor 20,each alternate jaw 32 belongs to the jaw set 36 a or 36 b, respectively.When the eccentric shafts 38 rotate, the jaw sets 36 a and 36 b aremoved in eccentric parallel paths, while being offset at the same time,so that when one jaw set, for example 36 a, is in its upper position,the jaw set 36 b is in its lowermost position. One or more partitionplates 44 divides the active area of the compactor 1 into two or morechannels.

[0033] On their underside, which will be in contact with the containers,the jaws 32 are provided with teeth 46 which are arranged to grip andpossibly also puncture the containers.

[0034] For the compacting of a container 5, containers 5 are placed onthe entrance side of the conveyor belt 28 above the driving motor 22. Ifthe compactor is provided with one or more partition plates 44, thechannel adapted for the packaging in question is selected. The first jawset 36 a and the second jaw set 36 b rotate at the same frequency and180 degrees out of phase. When the-container 5 touches one jaw set 38 awhich is moving in a direction towards the belt 28, one or more teeth 46of one or more jaws 32 will grip the container 5 and possibly punctureit. After the first jaw set 38 a has gripped the container, the jaw sets38 a, 38 b and the conveyor belt 28 together will pull the container 5further into the compacting area between the conveyor belt 28 and thejaw device 30. Since the jaw sets 38 a and 38 b are moving 180 degreesout of phase, at least one of the jaw sets 38 a, 38 b will always be incontact with the container 5. The eccentric and parallel movements ofthe jaw sets 38 a, 38 b will cause the teeth 46 of the jaw 32 to beforced into the container 5 before the container 5 is pulled forward.When the forward-pulling motion of the jaws 32 is complete, 180 degreeslater, the teeth 46 of the first jaw set 36 a are withdrawn from thecontainer 5 while the teeth 46 of the second jaw set 36 b aresimultaneously forced down into the container 5. The first jaw set 36 athen returns to its initial position by a 360 degrees' rotation of theshafts 38, and the sequence is repeated. This motion results in acontinuous compacting based on a series of partial compactings performedby the jaw sets 36 a and 36 b.

[0035] If a container 5 or another object which does not allowcompacting, enters the compactor 1, the gas spring 16 is arranged toyield by way of the release arm 14 which is supported on the rotationalpoint 15 and connected to the turning roller portion of the conveyorbelt 28, so that the conveyor belt pivots on the pivotal suspension 23,whereby the container 5 may pass through the compactor 1 without theconveyor belt 28 being overloaded, see FIG. 6.

[0036] In the following is described the compacting/processing of anumber of different containers 5. It is implied that terms like can,plastic bottle, glass bottle etc. refer to kinds of containers 5.

[0037] Compacting of beverage cans of metal is effected in that thebeverage cans are pressed flat individually, so that cans of steel andaluminium may easily be separated in subsequent processing. Somebeverage cans are provided with a built-in 5 gas cartridge. The aim ofthe gas cartridge is to produce foam in the content of the can, e.g.beer, when the can is opened by the consumer. It is essential that thedevice 1 is arranged to compact cans containing these kinds of gascartridges.

[0038] The compacting of plastic bottles with screwed-on caps requirespuncturing of the bottle before compacting. Without puncturing, thebottle will return to its original shape after having been compacted,because of the air pressure formed inside the bottle. In at least oneportion of the jaw 32, the jaws 32, which are arranged to compactplastic bottles, are provided with teeth 46 formed by two peaks besideeach other relative to the longitudinal direction of the jaw 32. Plasticbottles with caps may contain liquid, and this liquid may cause problemsfor the compactor 1 and the collecting packaging. Normally the amount ofliquid per bottle will be limited because the container is normallyweighed in a device located upstream relative to the compactor 1.Containers 5 with too much liquid are returned to the user. It willstill be possible for containers containing liquid to be admitted intothe compactor 1. The puncturing is therefore done by means of the jaws32 which are located above the container, whereby a considerableproportion of possible liquid will remain in the container without thisleading to unnecessary spillage within the compactor and in thecollecting cases/bags.

[0039] Compacting of glass bottles is effected in that the bottle 5 isbroken by a quick blow against a limited part of the bottle 5, so-calledhammering. The bottle 5 will then separate into a number of fragmentsdepending on the type of glass. The fragments will be carried out of thecompactor by means of the belt conveyor.

[0040] In the manner described above, a quick, simple and efficientcompacting of containers 5 is achieved, without this causing unnecessarywear on the device 1. The operating costs for the device 1 will therebybe low. The chamber and associated jaws 32 of the compactor 1 may easilybe adapted for the type of material to be compacted without thischanging the basic structure of the compactor.

[0041] Any configuration of the jaws is possible as long as thereceiving area between the jaw sets 36 a, 36 b and the conveyor belt 20is essentially cuneiform, and the teeth 46 of the jaws 32 perform thetask intended relative to the type of material to be processed.

1. A compactor device for compacting containers (5), for exampledisposable bottles/cans of metal, plastic, glass or other suitablematerial, whereby the container (5) is essentially pressed flat andpossibly punctured, possibly crushed, characterized in that thecompacting area is formed by a cuneiform area between a conveyor belt(20) and a first jaw set (36 a) and a second jaw set (36 b), wherein aplurality of jaws (32) which are provided with teeth (46) on theiractive side, are arranged in such a way that preferably each alternatejaw (32), as seen transversally to the longitudinal direction of theconveyor belt (20), is connected to the jaw sets (36 a) and (36 b)respectively, the jaw sets (36 a) and (36 b) being rotatably connectedto two common rotatable eccentric shafts (38, 38′), the eccentric shafts(38, 38′) being so formed that the eccentric motion of the jaw sets (36a, 36 b) is out of phase, typically by 180 degrees.
 2. A deviceaccording to claim 1, characterized in that the conveyor belt (28) isprovided with a support plate (26) below the conveyor belt (28), thesupport plate (26) being arranged to form a holding-up means against thejaws (32) during compacting.
 3. A device according to one or more of thepreceding claims, characterized in that individually or in groups, theteeth (46) of the jaws (32) are arranged to perform gripping,puncturing, hammering or pressing flat of the container (5).
 4. A deviceaccording to one or more of the preceding claims, characterized in thatthe compactor (1) is provided with one or more partition plates (44),which are arranged to form channels through the compactor (1).
 5. Adevice according to one or more of the preceding claims, characterizedin that jaws (32) which are arranged to compact plastic bottles areprovided, at least on part of the jaw (32), with teeth (46) formed bytwo peaks beside each other relative to the longitudinal direction ofthe jaw (32).
 6. A device according to one or more of the precedingclaims, characterized in that the compactor (1) is provided with aspring device (16), for example a gas spring, which is connected by arelease arm (14) to the discharge end portion of the conveyor belt (20),and is arranged, on overloading of the conveyor belt (28), to lower theconveyor belt (20) with the aim of preventing overloading of thecompactor (1).